Rubber composition and pneumatic tire using same

ABSTRACT

Provided is a rubber composition which contains a diene rubber and a reinforcing filler, and the diene rubber contains a styrene-butadiene copolymer component including at least one type of styrene-butadiene copolymer and satisfying: (1) the bonded styrene content is from 5 to 50 wt. %; (2) among components obtained by ozone decomposition, a content of a decomposed component V1 containing one 1,2-bonded butadiene-derived unit out of a total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is not less than 20 mol %; (3) among components obtained by ozone decomposition, a content of a decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit out of a total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is less than 4 mol %; and (4) a vinyl content of a butadiene moiety is not less than 20% and less 50%.

TECHNICAL FIELD

The present technology relates to a rubber composition which improves tensile strength at break and tensile elongation at break to or beyond known levels, and a pneumatic tire using the same.

BACKGROUND ART

In recent years, there has been a demand for high wet grip performance and low rolling resistance in pneumatic tires. A known technique for satisfying these demands is to blend a reinforcing filler such as a styrene-butadiene copolymer or silica into a rubber composition constituting the cap tread of a tire. Further, to enhance the wear resistance, rubber hardness, or modulus of repulsion elasticity of the rubber composition, it has been proposed to blend a polybutadiene or silica having high reactivity, for example, but this is problematic in that the rubber strength decreases or the workability is diminished.

Japan Unexamined Patent Publication No. H03-239737 describes that a pneumatic tire in which a rubber composition prepared by blending a styrene-butadiene copolymer having a specific array of styrene units and silica is used for a tread simultaneously satisfies wet skid resistance, rolling resistance, and wear resistance. However, this rubber composition is not necessarily capable of sufficiently enhancing tensile strength at break and tensile elongation at break, and is therefore not capable of sufficiently satisfying the demands of consumers.

Japan Unexamined Patent Publication No. S57-179212 describes that an ozone-decomposed product of a styrene-butadiene copolymer is analyzed by gel permeation chromatography (GPC), and the content ratio of a long-chain styrene block with respect to the total styrene content and the content ratio of a simple chain with one styrene unit are measured. A styrene-butadiene copolymer in which the long-chain styrene block content is not greater than 5 wt. % and the simple chain content with one styrene unit is not less than 50 wt. % with respect to the total styrene content in the styrene-butadiene copolymer, and the total styrene content is from 10 to 30 wt. % of the styrene-butadiene copolymer is then described. However, a rubber composition made of this styrene-butadiene copolymer is not necessarily capable of sufficiently enhancing the rubber strength, rubber hardness, wear resistance, and low hysteresis loss thereof. In addition, in the GPC-based analysis in Japan Unexamined Patent Publication No. S57-179212, even in a case where the ozone-decomposed product of the styrene-butadiene copolymer can be classified based on the number of styrene units and a chain made of only styrene units, the number of units derived from 1,2-bonds of butadiene in the ozone-decomposed product cannot be identified. Further, in the GPC-based analysis of Japan Unexamined Patent Publication No. S57-179212, the ratio of the styrene content in the decomposition product to the total styrene content is calculated, and the amount of each decomposition product is not accurately quantified.

SUMMARY

The present technology provides a tire rubber composition which improves tensile strength at break and tensile elongation at break to or beyond known levels.

The rubber composition of the present technology includes a diene rubber containing at least one type of styrene-butadiene copolymer, and a reinforcing filler; wherein the styrene-butadiene copolymer including at least one type of styrene-butadiene copolymer has the following characteristics (1) to (4):

(1) the bonded styrene content is from 5 to 50 wt. %;

(2) among components obtained by ozone decomposition, a content of a decomposed component V1 containing one 1,2-bonded butadiene-derived unit out of a total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is not less than 20 mol %;

(3) among components obtained by ozone decomposition, a content of a decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit out of a total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is less than 4 mol %; and

(4) a vinyl content of a butadiene moiety is not less than 20% and less than 50%.

According to the configuration described above, the rubber composition of the present technology includes a diene rubber containing a styrene-butadiene copolymer component and a reinforcing filler to satisfy the following: (1) the bonded styrene content is from 5 to 50 wt. %; (2) among components obtained by ozone decomposition, the content of a decomposed component V1 containing one 1,2-bonded butadiene-derived unit out of the total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is not less than 20 mol %; (3) among components obtained by ozone decomposition, the content of a decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit out of the total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is less than 4 mol %; and (4) the vinyl content of a butadiene moiety is not less than 20% and less than 50%. Therefore, the rubber composition of the present technology can improve tensile strength at break and tensile elongation at break to or beyond known levels.

The diene rubber described above may contain at least one other type of diene rubber excluding the styrene-butadiene copolymer described above. In addition, the reinforcing filler may be at least one type selected from silica and carbon black.

The rubber composition described above is suitable for use in a pneumatic tire and may be used in a cap tread, in particular. This pneumatic tire can improve breakdown resistance and durability to or beyond known levels.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is an example of a calibration curve illustrating the correlation between the concentration and ionic strength of a standard sample.

FIG. 2 is another example of a calibration curve illustrating the correlation between the concentration and ionic strength of a standard sample.

FIG. 3 is an explanatory diagram illustrating the relationship between a chain component and the slope of the calibration curve, and the slope of an estimated calibration curve.

FIG. 4 is an explanatory diagram illustrating the relationship between another chain component and the slope of the calibration curve, and the slope of an estimated calibration curve.

FIG. 5 is an explanatory diagram illustrating the relationship between yet another chain component and the slope of the calibration curve, and the slope of an estimated calibration curve.

FIG. 6 is a partial cross-sectional view in a tire meridian direction that illustrates an example of an embodiment of a pneumatic tire in which a rubber composition according to an embodiment of the present technology is used.

DETAILED DESCRIPTION

FIG. 6 is a partial cross-sectional view illustrating an example of an embodiment of a pneumatic tire in which a rubber composition is used. The pneumatic tire is formed from a tread portion 1, a sidewall portion 2, and a bead portion 3.

In FIG. 6, two carcass layers 4, formed by arranging reinforcing cords extending in a tire circumferential direction at a predetermined pitch in the tire circumferential direction and embedding these reinforcing cords in a rubber layer, extend between left and right bead portions 3. Both ends thereof are made to sandwich a bead filler 6 and are folded back around a bead core 5 that is embedded in the bead portions 3 in a tire axial direction from the inside to the outside. An inner liner 7 is disposed inward of the carcass layers 4. Two layers of a belt layer 8, formed by arranging reinforcing cords extending inclined to the tire circumferential direction in the tire axial direction at a predetermined pitch and embedding these reinforcing cords in a rubber layer, is disposed on an outer circumferential side of the carcass layer 4 of the tread portion 1. The inclination direction with respect to the tire circumferential direction of the reinforcing cords of the two belt layers 8 intersect so as to be opposite each other in the tire circumferential direction. A belt cover layer 9 is disposed outward of the belt layers 8. The tread portion 1 is formed from tread rubber layers 10 a and 10 b on the outer circumferential side of the belt cover layer 9. The tread rubber layers 10 a and 10 b are a cap tread and a base tread and may preferably be made of the rubber composition of the present technology.

The rubber composition of the present technology includes a diene rubber and a reinforcing filler. The diene rubber necessarily contains at least one type of styrene-butadiene copolymer. In this specification, a polymer component including at least one type of styrene-butadiene copolymer may also be called a “styrene-butadiene copolymer component”. In the present technology, the styrene-butadiene copolymer component satisfies all of the following characteristics (1) to (4):

(1) the bonded styrene content is from 5 to 50 wt. %;

(2) among components obtained by ozone decomposition, the content of a decomposed component V1 containing one 1,2-bonded butadiene-derived unit out of the total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is not less than 20 mol %;

(3) among components obtained by ozone decomposition, the content of a decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit out of the total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is less than 4 mol %; and

(4) the vinyl content of a butadiene moiety is not less than 20% and less than 50%.

When the styrene-butadiene copolymer component is made of a single styrene-butadiene copolymer, the styrene-butadiene copolymer needs to satisfy all of the characteristics (1) to (4) described above.

In addition, when the styrene-butadiene copolymer component is made of a blend of a plurality of styrene-butadiene copolymers, the styrene-butadiene copolymer component needs to satisfy all of the characteristics (1) to (4) described above on the whole. As long as the styrene-butadiene copolymer component satisfies all of the characteristics (1) to (4) on the whole, each individual styrene-butadiene copolymer forming the blend may or may not satisfy all of the characteristics (1) to (4) described above. Each individual styrene-butadiene copolymer forming the blend preferably satisfies all of the characteristics (1) to (4). The styrene-butadiene copolymer component including from two or more types of styrene-butadiene copolymers satisfying all of the characteristics (1) to (4) can achieve excellent tensile strength at break and tensile elongation at break of the rubber composition.

In the present technology, the styrene-butadiene copolymer component (1) has a bonded styrene content from 5 to 50 wt. % and preferably from 10 to 40 wt. %. A styrene content of the styrene-butadiene copolymer component within such a range can achieve the balance between the tensile strength at break and tensile elongation at break of the rubber composition and the wet skid characteristics. In a case where the styrene content of the styrene-butadiene copolymer component is less than 5 wt. %, the wet skid characteristics, tensile strength at break, and tensile elongation at break will be diminished. In a case where the styrene content of the styrene-butadiene copolymer component exceeds 50 wt. %, the glass transition temperature (Tg) of the styrene-butadiene copolymer component will rise, the balance between viscoelastic characteristics will worsen, and heat build-up will become large. That is, the balance between the hysteresis loss and wet skid characteristics will be diminished. Note that the styrene content of the styrene-butadiene copolymer component is measured by ¹H-NMR (proton nuclear magnetic resonance).

The decomposed components of the styrene-butadiene copolymer component used in the present technology obtained by ozone decomposition are measured with a mass spectrometer which performs classification in two stages by liquid chromatography using two columns with different characteristics (also called “LC-LCMS analysis” hereafter). The composition and volume of ozone decomposed components can be analyzed in detail with this LC-LCMS analysis, and units derived from 1,2-bonds of butadiene can be quantified in addition to the styrene-derived units in the ozone-decomposed components.

A styrene-butadiene copolymer is a copolymer of styrene and butadiene and includes repeating units of styrene (styrene units) and repeating units of butadiene (butadiene units). The butadiene units include a portion in which butadiene is polymerized by 1,2-bonds (repeating units of ethylene having a vinyl group in the side chain) and a portion in which butadiene is polymerized by 1,4-bonds (repeating units of a divalent group of 2-butylene). In addition, the portion polymerized by 1,4-bonds includes repeating units of trans-2-butylene structures and repeating units of cis-2-butylene structures.

When the styrene-butadiene copolymer is ozone-decomposed, the butadiene moiety polymerized by 1,4-bonds is cleaved. In addition, the vinyl groups in the side chain of the butadiene moiety polymerized by 1,2-bonds are oxidized to form hydroxymethyl groups. As a result, in the styrene-butadiene copolymer, repeating units sandwiched between two adjacent butadiene units polymerized by a 1,4-bonds are produced as ozone-decomposed components. For example, when a portion in which only one 1,2-bonded butadiene in a main chain is sandwiched between two butadiene units polymerized by 1,4-bonds is ozone-decomposed, a compound represented by the following general formula (I) is produced. In this specification, a composition represented by general formula (I) is called an “ozone-decomposed component V1”. Note that in this specification, the direction of linkage with adjacent units may be either a head-to-tail bond or a head-to-head bond, and head-to-tail bonds/head-to-head bonds expressed by the chemical formula are interchangeable with one another.

In addition, when a portion in which two styrene units and one butadiene units polymerized by 1,2-bonds in a main chain are sandwiched between adjacent butadiene units polymerized by 1,4-bonds is ozone-decomposed, a compound represented by the following general formula (II) is produced. In this specification, a decomposed component including two styrene-derived units and one butadiene-derived unit polymerized by 1,2-bonds is called an “ozone-decomposed component S2V1”.

Note that the compound represented by general formula (II) described above also includes compounds in which at least one element selected from the alignment sequence of the two styrene-derived units and the one 1,2-bonded butadiene-derived unit, the head-to-tail bonds/head-to-head-bonds, and the alignment sequence thereof differs.

The portion sandwiched between two adjacent butadiene units polymerized by 1,4-bonds as described above is produced as a decomposed component in which styrene-derived units and or 1,2-bonded butadiene-derived units are sandwiched by hydroxyethyl groups at both ends due to ozone decomposition. In addition, 1,4-butanediol is produced from the repeating portion having two or more consecutive butadiene units polymerized by 1,4-bonds.

When the decomposed components obtained by ozone decomposition in the styrene-butadiene copolymer component used in the present technology are measured by LC-LCMS analysis, (2) among components obtained by ozone decomposition, the content of a decomposed component V1 containing one 1,2-bonded butadiene-derived unit out of the total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is not less than 20 mol %. A decomposed component containing one 1,2-bonded butadiene derived unit refers to an ozone-decomposed component V1 containing only one 1,2-bonded butadiene-derived unit, as described above. The number of moles of each decomposed component is determined by measuring the ozone-decomposed component using LC-LCMS analysis. Next, the total number of moles of the decomposed components including styrene-derived units and/or 1,2-bonded butadiene-derived units produced by ozone decomposition is calculated, and this is defined as 100 mol % of the ozone-decomposed component. The amount of the decomposed component V1 containing one 1,2-bonded butadiene-derived unit is not less than 20 mol % and is preferably not less than 20 mol % and less than 45 mol % out of 100 mol % of the ozone-decomposed component. By setting the content of the ozone-decomposed component V1 to not less than 20 mol %, the tensile strength at break and tensile elongation at break can be enhanced.

In addition to the above, the styrene-butadiene copolymer component used in the present technology satisfies the characteristic (3): when the decomposed components obtained by ozone decomposition are measured by LC-LCMS analysis, the content of a decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit is less than 4 mol % and is preferably not less than 2 mol % and less than 4 mol %. Here, the ozone-decomposed component S2V1 is an ozone-decomposed component containing two styrene-derived units and one 1,2-bonded butadiene-derived unit, as described above, and corresponds to the decomposed component represented by general formula (II) described above. The number of moles of the decomposed component represented by general formula (II) is determined by measuring the ozone-decomposed component using LC-LCMS analysis. When the total number of moles of the decomposed component containing styrene-derived units and/or 1,2-bonded butadiene-derived unit is calculated as defined as 100 mol % of the ozone-decomposed component, the content of the decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit need to be less than 4 mol %. As a result, the tensile strength at break and tensile elongation at break can be enhanced.

In this specification, the method of ozone-decomposing the styrene-butadiene copolymer component and the measurement of the ozone-decomposed product are performed in accordance with the methods described in Tanaka et al. (Polymer, 22, 1721 (1981)) and (Macromolecules, 16, 1925 (1983)). Note that in the analytical methods described by Tanaka et al., the total amount of an ozone-decomposed component S1 containing only one styrene-derived unit and an ozone-decomposed component S1Vn (where n is an integer of 1 or greater) containing one styrene-derived unit and one or more 1,2-bonded butadiene-derived units is called a “styrene simple chain”. In contrast, in the present technology, as described above, analysis is performed individually by LC-LCMS analysis while focusing attention on the numbers of moles of the ozone-decomposed component S1 containing only one styrene-derived unit and the ozone-decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit.

In this specification, the conditions for measuring the ozone-decomposed component with LC-LCMS analysis may be as follows.

Liquid chromatograph: comprehensive two-dimensional LC Nexera-e (available from Shimadzu Corporation)

Mass spectrometer: LCMS-8040 or LCMS-8050 (both available from Shimadzu Corporation)

First-dimensional column: A total of three columns were linked in series and used, including two columns (A) in which the stationary phase is a polymer gel (Shodex Mspak GF-310 2D available from Showa Denko K.K., inner diameter: 2.0 mm, length: 150 mm, particle size: 5 μm) and one column (B) in which the stationary phase is a polymer gel (Super HZ 1000 available from Toso Corporation, inner diameter: 2.0 mm, length 250 mm, particle size: 3 μm).

Injection volume: 1 μL (sample solution concentration: 10 mg/mL)

Mobile phase: THF

Flow rate: 0.02 mL/min

Second-dimensional column: Column (A) in which the stationary phase is a core-shell polymer gel modified with an octadecyl group (Kinetex C18 available from Phenomenex Corporation, inner diameter: 3.0 mm, length: 50 mm, particle size: 2.6 μm)

Mobile phase A: water:methanol=1:1

Mobile phase B: methanol

Flow rate: 2.0 mL/min

Time program: B conc. 20% (0 min)→100% (0.75 min)→20% (0.76 min)→STOP (1 min)

Interface temperature: 350° C.

Desolventizing temperature: 200° C.

Interface voltage: 4.5 V

Interface (ionization method): (APCI positive mode)

Mass spectrometry conditions: SIM measurements: 9 events (ev1: S1-S1V10, ev2: S2-S2V10, ev3: S3-S3V10, ev4: S4-S4V10, ev5: S5-S5V10, ev6: S6-S6V10, ev7: S7-S7V10, ev8: S8-S8V10, ev9: V1-V10), total of 98 ch SIM+each individual SIM: 98 events (for calibration curve creation), total of 107 events

Detection ion: protonated ion (m/z=[M+H]+)

Here, a commercially available sample may be used for a standard sample, or a sample isolated from an ozone-decomposed product of SBR and having a purity calculated by NMR (nuclear magnetic resonance) or the like may be used. For example, standard samples may be prepared as follows.

A solution-polymerized SBR having a styrene content of 36 wt. % and a vinyl content of 42% in butadiene was subjected to ozone decomposition treatment, and a total of seven components—S1, S1V1, S2, S2V1, S3, S3V1, and V1—were batched with a chloroform solvent using LC-9104 (batching GPC) available from Japan Analytical Industry Co., Ltd. and four low-molecular-weight columns (two of each of JAIGEL-1H and JAIGEL-2H). The purity was calculated by NMR, and these were used as standard samples.

Polybutadiene having a vinyl content of 70% was subjected to ozone decomposition treatment, and after the dissolution times of the components were first confirmed under the mass spectrometry ionization condition APCI+ in a gradient measurement of 20% B-100% B for 40 minutes at a flow rate of 1 mL/min and an injection volume of 0.2 μL using a column (VP-ODS 150 mm×4.6 mm) and using water as a mobile phase A and methanol as a mobile phase B in an HPLC system Prominence available from Shimadzu Corporation, V1, V2, and V3 were batched off at these times. The purity was calculated by NMR, and these were used as standard samples.

In addition, LC-LCMS analysis may be performed in accordance with the following operations.

Analysis is performed using LCMS-8040 (product name) or LCMS-8050 (product name) available from Shimadzu Corporation, and the standard samples obtained as described above are measured using the APCI positive MS mode.

Based on the detection results of the mass spectrometer, a correlation diagram (calibration curve) of the concentration and ionic strength of each standard sample was created. The correlation diagrams that were created are illustrated in FIGS. 1 and 2. In FIGS. 1 and 2, symbols such as “S1V1”, “V1”, and “S2” represent the number of 1,2-bonded butadiene-derived units and the number of styrene-derived units illustrating the calibration curve. For example, the symbol “S1V1” expresses that the compound has one 1,2-bonded butadiene-derived unit and one styrene-derived unit. As can be seen from FIGS. 1 and 2, it is clear that the calibration curves differ depending on the number of styrene-derived units and the number of 1,2-bonded butadiene-derived units contained in the compound.

Calibration Curve Estimate

In the case of SBR with an unknown structure, there are various types of ozone-decomposed components thereof, and a qualitative analysis of all decomposed components cannot be made with only the calibration curves of the compounds illustrated in FIGS. 1 and 2. Therefore, calibration curves of decomposed components having an unknown mass-charge ratio were estimated from the calibration curves determined for the standard samples described above.

Specifically, for a chain component Sn containing only styrene, the amount of change in the slope of the calibration curve when the number of chains of styrene increases by one was determined by calculation from the calibration curves of S1 to S3, and the slope of the chain component Sn (n≥4) was estimated. The slope of the calibration curve was estimated with a similar method for a chain component (Vm) containing 1,2-bonded butadiene-derived units. The slopes of the estimated calibration curves are illustrated in FIG. 3.

On the other hand, for a chain component (SnVm) containing styrene-derived units and 1,2-bonded butadiene-derived units, the degrees of contribution of the styrene and 1,2-bonded butadiene-derived units to the slope of the calibration curve were determined from the amount of change in the slope when the number of chains of styrene was fixed and the number of chains of 1,2-bonded butadiene was varied and the amount of change in the slope when the number of chains of 1,2-bonded butadiene was fixed and the number of chains of styrene was varied, and the slope of the calibration curve of the chain component SnVm was estimated from the degrees of contribution and the numbers of chains of styrene and 1,2-bonded butadiene-derived units. FIGS. 3 to 5 illustrate the slopes of the calibration curves of chain components determined from the results of actual measurements and the slopes of the calibration curves estimated in accordance with the method described above. Creation of two-dimensional chromatogram

Next, the ozone-decomposed product was analyzed by LC-LCMS. The devices and analysis conditions used for analysis are the same as those used for the creation of a calibration curve.

The detection results of the mass spectrometer were analyzed using ChromSquare analysis software (available from Shimadzu Corporation), and a two-dimensional chromatogram was created, wherein the elution time of the primary column is expressed by horizontal axis, the elution time of the secondary column is expressed by the vertical axis, and the signal intensity is expressed by a contour line. By using LC×LC, even components such as S2V1 and S1V1 with very similar elution times can be separated. Thus, the chain structures of the styrene-derived units and 1,2-bonded butadiene-derived units contained in the sample can be identified.

The styrene-butadiene copolymer component used in the present technology satisfies the characteristic (4): the vinyl content of the butadiene moiety is not less than 20% and less than 50%, and is preferably from 21 to 49%. By setting the vinyl content of the butadiene moiety to not less than 20% and less than 50% in the styrene-butadiene copolymer component, the tensile strength at break and tensile elongation at break can be maintained and enhanced. Note that the vinyl content of the butadiene moiety is measured by ¹H-NMR.

The content of the styrene-butadiene copolymer component having the characteristics (1) to (4) is preferably not less than 40 wt. %, more preferably from 60 to 100 wt. %, and even more preferably from 80 to 100 wt. % per 100 wt. % of the diene rubber. By setting the content of the styrene-butadiene copolymer component specified by the characteristics (1) to (4) to not less than 40 wt. %, the tensile strength at break of the rubber composition can be enhanced, and the tensile elongation at break can be maintained and improved.

The rubber composition of the present technology may contain another diene rubber other than the styrene-butadiene copolymer component satisfying all of the characteristics (1) to (4). Examples of other diene rubbers include natural rubber (NR), polyisoprene rubber (IR), polybutadiene rubber (low-cis BR), high-cis BR, high-trans BR (trans-bond content of butadiene moiety: 70 to 95%), styrene-isoprene copolymer rubber, butadiene-isoprene copolymer rubber, solution polymerized random styrene-butadiene-isoprene copolymer rubber, emulsion polymerized random styrene-butadiene-isoprene copolymer rubber, emulsion polymerized styrene-acrylonitrile-butadiene copolymer rubber, acrylonitrile-butadiene copolymer rubber, high-vinyl SBR/low-vinyl SBR block copolymer rubber, polyisoprene-SBR block copolymer rubber, and polystyrene-polybutadiene-polystyrene block copolymers.

The content of the other diene rubber is preferably not greater than 60 wt. %, more preferably from 0 to 40 wt. %, and even more preferably from 0 to 20 wt. % per 100 wt. % of the diene rubber. Containing another diene rubber enables the enhancement of various physical properties such as wear resistance.

The rubber composition of the present technology contains a diene rubber and a reinforcing filler. Examples of reinforcing fillers include inorganic fillers such as carbon black, silica, clay, aluminum hydroxide, calcium carbonate, mica, talc, aluminum oxide, titanium oxide, and barium sulfate, and organic fillers such as cellulose, lecithin, lignin, and dendrimer. Of these, at least one type selected from carbon black and silica is preferably compounded.

By compounding carbon black into the rubber composition, the tensile strength at break of the rubber composition can be enhanced. The compounded amount of the carbon black is not particularly limited but is preferably from 10 to 100 parts by weight and more preferably from 25 to 80 parts by weight per 100 parts by weight of the diene rubber.

Carbon black such as furnace black, acetylene black, thermal black, channel black, and graphite may be compounded as the carbon black. Of these, furnace black is preferably used. Specific examples include SAF (Super Abrasion Furnace), ISAF (Intermediate Super Abrasion Furnace), ISAF-HS (Intermediate Super Abrasion Furnace High Structure), ISAF-LS (Intermediate Super Abrasion Furnace Low Structure), IISAF-HS (Intermediate Intermediate Super Abrasion Furnace High Structure), HAF (High Abrasion Furnace), HAF-HS (High Abrasion Furnace High Structure), HAF-LS (High Abrasion Furnace Low Structure), and FEF (Fast Extruding Furnace). These carbon blacks may each be used alone, or a combination of two or more types of carbon blacks may be used. In addition, surface-treated carbon blacks in which these carbon blacks are chemically modified with various acid compounds or the like may also be used.

Further, by compounding silica into the rubber composition, the low heat build-up and wet grip performance of the rubber composition can be enhanced. The compounded amount of the silica is not particularly limited but is preferably from 10 to 150 parts by weight and more preferably from 40 to 100 parts by weight per 100 parts by weight of the diene rubber.

The silica may be any silica that is regularly used in rubber compositions for use in tire treads, and examples thereof include wet silica, dry silica, or surface-treated silica which is surface-treated by a compound which is reactive or compatible with both silica and rubber such as carbon-silica in which silica is supported on a carbon black surface (dual-phase filler), a silane coupling agent, or a polysiloxane. Of these, a wet silica having hydrous silicic acid as a main component is preferably used.

In the present technology, the compounded amount of the reinforcing filler containing silica and/or carbon black is preferably from 10 to 150 parts by weight and more preferably from 40 to 100 parts by weight per 100 parts by weight of the diene rubber. When the compounded amount of the reinforcing filler is less than 10 parts by weight, the reinforcing performance cannot be sufficiently achieved, and the tensile strength at break becomes insufficient. In addition, when the compounded amount of the reinforcing filler exceeds 150 parts by weight, heat build-up increases, while tensile elongation at break decreases.

Since the rubber composition of the present technology contains silica as well as a silane coupling agent, the low heat build-up and tensile elongation at break are further enhanced, which is preferable. Since a silane coupling agent is blended together with the silica, the dispersibility of the silica is improved, and the reinforcement action with respect to the diene rubber is further increased. The compounded amount of the silane coupling agent is preferably from 2 to 20 wt. % and more preferably from 5 to 15 wt. % of the compounded amount of the silica. In a case where the compounded amount of the silane coupling agent is less than 2 wt. % of the weight of the silica, the effect of improving the dispersion of the silica cannot be sufficiently obtained. In addition, when the compounded amount of the silane coupling agent exceeds 20 wt. %, the diene rubber component will tend to be easily gelified. Thus, the desired effect cannot be achieved.

The silane coupling agent is not particularly limited, and a sulfur-containing silane coupling agent is preferable. Examples thereof include bis(3-triethoxysilylpropyl)tetrasulfide, bis(3-triethoxysilylpropyl)trisulfide, bis(3-triethoxysilylpropyl)disulfide, bis(2-triethoxysilylethyl)tetrasulfide, bis(3-trimethoxysilylpropyl)tetrasulfide, bis(2-trimethoxysilylethyl)tetrasulfide, 3-mercaptopropyltrimethoxysilane, 3-mercaptopropyldimethoxymethylsilane, 3-mercaptopropyldimethylmethoxysilane, 2-mercaptoethyltriethoxysilane, 3-mercaptopropyltriethoxysilane, mercaptosilane compounds disclosed in JP 2006-249069 A such as VP Si363 available from Evonik Corporation, 3-trimethoxysilylpropyl benzothiazole tetrasulfide, 3-triethoxysilylpropyl benzothiazole tetrasulfide, 3-triethoxysilylpropyl methacrylate monosulfide, 3-trimethoxysilylpropyl methacrylate monosulfide, 3-trimethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 3-triethoxysilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, 2-triethoxysilylethyl-N,N-dimethylthiocarbamoyl tetrasulfide, bis(3-diethoxymethylsilylpropyl)tetrasulfide, dimethoxymethylsilylpropyl-N,N-dimethylthiocarbamoyl tetrasulfide, dimethoxymethylsilylpropyl benzothiazole tetrasulfide, 3-octanoylthiopropyl triethoxysilane, 3-propionylthiopropyl trimethoxysilane, vinyl trimethoxysilane, vinyl triethoxysilane, vinyl tris(2-methoxyethoxy)silane, 3-glycidoxypropyl trimethoxysilane, 3-glycidoxypropylmethyl dimethoxysilane, β-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-aminopropyl trimethoxysilane, N-(β-aminoethyl)-γ-aminopropyl trimethoxysilane, and N-(β-aminoethyl)-γ-aminopropylmethyl dimethoxysilane. In addition, the silane coupling agent may be an organic silicon compound, and examples of organic silicon compounds include polysiloxane, silicone oils in which one or more organic group such as an amino group, an epoxy group, a carbinol group, a mercapto group, a carboxyl group, a hydrogen group, a polyether group, a phenol group, a silanol group, an acryl group, a methacryl group, or a long-chain alkyl group is introduced in the side chain, both ends, one end, or the side chain and both ends of polysiloxane, and silicone oligomers obtained by subjecting one or more types of organic silanes to a condensation reaction. Of these, bis-(3-triethoxysilylpropyl)tetrasulfide and bis(3-triethoxysilylpropyl) disulfide are preferable.

In accordance with known methods, the rubber composition of the present technology may also include, in addition to the components described above, various compounding agents that are commonly used in rubber compositions for use in tire treads. Examples thereof include vulcanization or crosslinking agents, vulcanization accelerators, anti-aging agents, processing aids, plasticizers, liquid polymers, thermosetting resins, and thermoplastic resins. These compounding agents can be kneaded by a common method to obtain a composition that can then be used for vulcanization or crosslinking. These compounding agents can be blended at known, general compounded amounts so long as the present technology are not hindered. The rubber composition for use in tire treads can be prepared by mixing the above-mentioned components using a well-known rubber kneading machine such as a Banbury mixer, a kneader, a roller, or the like.

The vulcanizing or crosslinking agent is not particularly limited, and examples thereof include sulfurs such as powdered sulfur, precipitated sulfur, colloidal sulfur, insoluble sulfur, and high-dispersibility sulfur; halogenated sulfurs such as sulfur monochloride and sulfur dichloride; and organic peroxides such as dicumyl peroxide and di-tert-butyl peroxide. Of these, sulfur is preferable, and powdered sulfur is particularly preferable. These vulcanizing or crosslinking agents may each be used alone, or a combination of two or more types may be used. The compounding ratio of the vulcanizing agent is ordinarily from 0.1 to 15 parts by weight, preferably from 0.3 to 10 parts by weight, and even more preferably from 0.5 to 5 parts by weight per 100 parts by weight of the diene rubber.

The vulcanization accelerator is not particularly limited, but examples thereof include sulfenamide-based vulcanization accelerators such as N-cyclohexyl-2-benzothiazyl sulfenamide, Nt-butyl-2-benzothiazol sulfenamide, N-oxyethylene-2-benzothiazol sulfenamide, and N,N′-diisopropyl-2-benzothiazol sulfenamide; guanidine-based vulcanization accelerators such as diphenyl guanidine, di-o-tolyl guanidine, and o-tolyl biguanidine; thiourea-based vulcanization accelerators such as diethylthiourea; thiazole-based vulcanization accelerators such as 2-mercaptobenzothiazole, dibenzothiazyl sulfide, and 2-mercaptobenzothiazole zinc salt; thiuram-based vulcanization accelerators such as tetramethylthiuram monosulfide and tetramethylthiuram disulfide; dithiocarbamic acid-based vulcanization accelerators such as sodium dimethyldithiocarbamate and zinc diethyldithiocarbamate; and xanthogenic acid-based vulcanization accelerators such as sodium isopropylxanthate, zinc isopropylxanthate, and zinc butylxanthate. Of these, a composition containing a sulfenamide-based vulcanization accelerator is particularly preferable. These vulcanization accelerators may each be used alone, or a combination of two or more types may be used. The compounded amount of the vulcanization accelerator is preferably from 0.1 to 15 parts by weight and more preferably from 0.5 to 5 parts by weight per 100 parts by weight of the diene rubber.

The anti-aging agent is not particularly limited, but examples thereof include amine-based anti-aging agents such as 2,2,4-trimethyl-1,2-dihydroquinoline polymers, p,p′-dioctyldiphenylamine, N,N′-diphenyl-p-phenylenediamine, and N-phenyl-N′-1,3-dimethylbutyl-p-phenylenediamine, and phenol-based anti-aging agents such as 2,6-di-t-butyl-4-methylphenol and 2,2′-methylene-bis(4-methyl-6-t-butylphenol). These anti-aging agents may each be used alone, or a combination of two or more types may be used. The compounded amount of the anti-aging agent is preferably from 0.1 to 15 parts by weight and more preferably from 0.5 to 5 parts by weight per 100 parts by weight of the diene rubber.

The processing aid is not particularly limited, and examples thereof that may be used include higher fatty acids such as stearic acid, higher fatty acid amides such as stearic acid amide, aliphatic higher amines such as stearyl amine, aliphatic higher alcohols such as stearyl alcohol, partial esters of a fatty acid and a polyhydric alcohol such as a glycerin fatty acid ester, fatty acid metal salts such as zinc stearate, and zinc oxide. The compounded amount is selected as needed, but the compounded amount of the higher fatty acid, aliphatic higher amide, higher alcohol, or fatty acid metal salt is preferably from 0.05 to 15 parts by weight and more preferably from 0.5 to 5 parts by weight per 100 parts by weight of the diene rubber. The compounded amount of zinc oxide is preferably from 0.05 to 10 parts by weight and more preferably from 0.5 to 3 parts by weight per 100 parts by weight of the diene rubber.

The plasticizer used as a compounding agent is not particularly limited, but an extender oil such as an aroma-based, naphthene-based, paraffin-based, or silicone-based oil may be selected in accordance with the application. The amount of the plasticizer that is used is ordinarily in the range from 1 to 150 parts by weight, preferably from 2 to 100 parts by weight, and even more preferably from 3 to 60 parts by weight per 100 parts by weight of the diene rubber. When the amount of the plasticizer that is used is within this range, the reinforcing agent dispersing effect, tensile strength, tensile elongation at break, heat resistance, and the like are balanced to a high degree. Other examples of plasticizers include diethylene glycol, polyethylene glycol, and silicone oils.

The thermosetting resin is not particularly limited, but examples thereof include thermosetting resins which are cured or polymerized by heating or by applying heat and a methylene donor, such as a resorcin-formaldehyde resin, a phenol-formaldehyde resin, a urea-formaldehyde resin, a melamine-formaldehyde resin, or a phenol derivative-formaldehyde resin—specifically, an m-3,5-xylenol-formaldehyde resin, a 5-methylresorcin-formaldehyde resin, or the like—and other resins such as a guanamine resin, a diallylphthalate resin, a vinyl ester resin, a phenol resin, an unsaturated polyester resin, a furan resin, a polyimide resin, a polyurethane resin, a melamine resin, a urea resin, or an epoxy resin.

The thermoplastic resin is not particularly limited, but example of wisely used thermoplastic resins include polystyrene resins, polyethylene resins, polypropylene resins, polyester resins, polyamide resins, polycarbonate resins, polyurethane resins, polysulfone resins, polyphenylene ether resins, and polyphenylene sulfide resins. Additional examples include aromatic hydrocarbon resins such as styrene-α-methylstyrene resins, indene-isopropenyl toluene resins, and coumarone-indene resins, dicyclopentadiene resins, hydrocarbon resins such as petroleum resins containing 1,3-pentadiene, pentene, methylbutene, or the like as a main raw material, alkylphenol resins, modified phenol resins, terpene phenol resins, terpene resins, and aromatic modified terpene resins.

Since the rubber composition of the present technology is configured so that the tensile strength at break and tensile elongation at break can be improved to or beyond known levels, the wear resistance and durability of a pneumatic tire can be enhanced to or beyond known levels.

The rubber composition of the present technology can be suitably used in the cap tread portion, undertread portion, sidewall portion, or bead filler portion of a pneumatic tire, a coating rubber for a cord such as a carcass layer, a belt layer, or a belt cover layer, a sectionally crescent side reinforcing rubber layer of a run-flat tire, a rim cushion portion, or the like.

The present technology is further described below by Examples. However, the scope of the present technology is not limited to these Examples.

EXAMPLES

Styrene-butadiene copolymer components were prepared by blending seven types of styrene-butadiene copolymers at the compounding ratios shown in Tables 1 and 2, and (1) the bonded styrene content (wt. %), (2) the mol % of an ozone-decomposed component V1 containing one 1,2-bonded butadiene-derived unit, (3) the mol % of an ozone-decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit, and (4) the vinyl content (wt. %) of the butadiene moiety were measured. In addition, since styrene-butadiene copolymers Tufdene 2330, NS570, NS460, NS522, and Nipol 1739 are oil extended products, the net compounded amounts of rubber components are indicated in parentheses together with the actual compounded amounts.

The values of (1) the bonded styrene content and (4) the vinyl content of the butadiene moiety of the styrene-butadiene copolymer component were measured by ¹H-NMR.

The conditions for the ozone decomposition of the styrene-butadiene copolymer component were as described above. In addition, (2) the mol % of an ozone-decomposed component V1 containing one 1,2-bonded butadiene-derived unit and (3) the mol % of an ozone-decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit were measured by LC-LCMS analysis under the conditions described above.

The components excluding sulfur and the vulcanization accelerator of 9 types of rubber compositions (Examples 1 to 5 and Comparative Examples 1 to 4) containing the compounding agents shown in Table 3 as common ingredients and containing a blend of the styrene-butadiene copolymer components shown in Tables 1 and 2 (blend of a plurality of styrene-butadiene copolymers) and other diene rubbers were mixed for 6 minutes using a 1.7-L sealed Banbury mixer, discharged from the mixer at 150° C., and then cooled to room temperature. Next, the mixture was mixed for 3 minutes using the 1.7-L sealed Banbury mixer again and discharged. Then, the sulfur and the vulcanization accelerators were mixed in using an open roll to prepare a rubber composition. The obtained rubber composition was vulcanized for 30 minutes at 160° C. in a predetermined mold to form a vulcanized rubber test piece. The obtained vulcanized rubber test piece was used to evaluate the tensile strength at break and tensile elongation at break using the following measurement methods. Tensile strength at break and tensile elongation at break

The obtained vulcanized rubber test piece was used to produce a dumbbell-shaped JIS No. 3 test piece in accordance with JIS K6251, and tensile tests were performed at room temperature (20° C.) and a tensile test speed of 500 mm/min to measure the tensile strength at break and tensile elongation at break at the time of the rupture of the test piece. The obtained results are shown in the “tensile strength at break” and “tensile elongation at break” rows of Tables 1 and 2, with the index value of Comparative Example 1 being 100. Larger index values of the “tensile strength at break” indicate stronger and superior tensile strength at break. Larger index values of the “tensile elongation at break” indicate stronger and superior tensile elongation at break.

TABLE 1 Compar- Compar- Compar- Compar- ative ative ative ative Exam- Exam- Exam- Exam- ple 1 ple 2 ple 3 ple 4 NS116 part by 70 70 70 weight Tufdene part by 41.25 2330 weight (30) NS570 part by 37.5 weight (30) NS522 part by 96.25 weight (70) 5360H part by 30 weight Nipol 1739 part by 41.25 weight (30) Oil part by 26.25 30 11.25 26.25 weight Bonded wt. % 26.6 26.8 35.7 22.4 styrene content Vinyl % 50.2 54.3 46.1 53.2 content V1 mol % 40.7 38.4 19.1 42.3 S2V1 mol % 3.3 3.5 2.6 6.6 Tensile Index 100 96 100 96 strength value at break Tensile Index 100 91 91 87 elongation value at break

TABLE 2 Exam- Exam- Exam- Exam- Exam- ple 1 ple 2 ple 3 ple 4 ple 5 NS116 part by 66.7 weight NS570 part by 41.63 78.75 weight (33.3) (63) NS460 part by 68.75 weight (50) 5360H part by 40 27 30 weight Nipol 1739 part by 68.75 55 96.25 weight (50) (40) (70) NR part by 20 weight BR part by 10 weight Oil part by 29.17 0 22.5 21.75 11.25 weight Bonded wt. % 27.1 32.4 33.7 36.7 36.1 styrene content Vinyl % 48.7 40.6 36.8 38.9 29.4 content V1 mol % 40.1 26.7 35.0 27.1 32.5 S2V1 mol % 3.2 3.1 2.9 2.9 2.3 Tensile Index 100 106 106 103 101 strength value at break Tensile Index 102 125 107 102 101 elongation value at break

The types of raw materials used in Tables 1 and 2 are as described below.

NS116: NS116 available from Zeon Corporation; bonded styrene content: 20.9 wt. %; vinyl content: 63.8%; non-oil extended product

Tufdene 2330: Tufdene 2330 available from Asahi Kasei Chemicals Corporation; bonded styrene content: 25.8 wt. %; vinyl content: 28.5%; oil component prepared by adding 37.5 parts by weight of an oil component to 100 parts by weight of SBR

NS570: NS570 available from Zeon Corporation; bonded styrene content: 40.6 wt. %; vinyl content: 19.0%; oil component prepared by adding 37.5 parts by weight of an oil component to 100 parts by weight of SBR

NS460: NS460 available from Zeon Corporation; bonded styrene content: 25.1 wt. %; vinyl content: 62.8%; oil component prepared by adding 37.5 parts by weight of an oil component to 100 parts by weight of SBR

NS522: NS522 available from Zeon Corporation; bonded styrene content: 39.2 wt. %; vinyl content: 42.2%; oil component prepared by adding 37.5 parts by weight of an oil component to 100 parts by weight of SBR

5360H: 5360H available from Korea Kumho Petrochemica Corporation; bonded styrene content: 27.6 wt. %; vinyl content: 55.2%; non-oil extended product

Nipol 1739: Nipol 1739 available from Zeon Corporation; bonded styrene content: 39.8 wt. %; vinyl content: 18.4%; oil component prepared by adding 37.5 parts by weight of an oil component to 100 parts by weight of SBR

NR: natural rubber, TSR 20

BR: Butadiene rubber; Nipol BR1220, available from Zeon Corporation

Oil: Extract No. 4S, available from Showa Shell Sekiyu K.K.

TABLE 3 Common formulation of rubber composition Silica 70.0 part by weight Silane coupling agent 5.6 part by weight Carbon black 5.0 part by weight Zinc oxide 3.0 part by weight Stearic acid 2.0 part by weight Anti-aging agent 1.5 part by weight Wax 1.0 part by weight Sulfur 1.5 part by weight Vulcanization accelerator 1 1.7 part by weight Vulcanization accelerator 2 2.0 part by weight

The types of raw materials used as per Table 3 are described below.

Silica: Nipsil AQ made by Nippon Silica Co., Ltd.

Silane coupling agent: sulfide-based silane coupling agent; Si69VP available from Evonik Degussa

Carbon black: Shoblack N339M, available from Showa Cabot K.K.

Zinc oxide: Zinc Oxide III available from Seido Chemical Industry Co., Ltd.

Stearic acid: stearic acid, available from NOF Corporation

Anti-aging agent: Santoflex 6PPD, available from Solutia Europe

Wax: paraffin wax, available from Ouchi Shinko Chemical Industrial Co., Ltd.

Sulfur: oil-treated sulfur, available from Karuizawa Refinery Ltd.

Vulcanization accelerator 1: Sanceller CM-PO (CZ), available from Sanshin Chemical Industry Co., Ltd.

Vulcanization accelerator 2: Sanceller D-G (DPG), available from Sanshin Chemical Industry Co., Ltd.

As is clear from Tables 1 and 2, it was confirmed that the rubber compositions of Examples 1 to 5 exhibited improved tensile strength at break and tensile elongation at break.

In the styrene-butadiene copolymer component of the rubber composition of Comparative Example 2, the vinyl content was not less than 50%. Thus, the tensile strength at break and tensile elongation at break were poor.

In the styrene-butadiene copolymer component of the rubber composition of Comparative Example 3, the content of the ozone-decomposed component V1 containing one 1,2-bonded butadiene-derived unit was less than 20 mol %. Thus, the tensile elongation at break was poor. In addition, a high tensile elongation at break cannot be achieved.

In the styrene-butadiene copolymer component of the rubber composition of Comparative Example 4, the vinyl content was not less than 50%, and the content of the ozone-decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit was not less than 4 mol %. Thus, the tensile strength at break and tensile elongation at break were poor. 

The invention claimed is:
 1. A rubber composition comprising: a diene rubber including at least one type of styrene-butadiene copolymer; and a reinforcing filler, wherein the styrene-butadiene copolymer including at least one type of styrene-butadiene copolymer has the following characteristics (1) to (4): (1) a bonded styrene content is from 5 to 50 wt. %; (2) among components obtained by ozone decomposition, a content of a decomposed component V1 containing one 1,2-bonded butadiene-derived unit out of a total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is not less than 20 mol %; (3) among components obtained by ozone decomposition, a content of a decomposed component S2V1 containing two styrene-derived units and one 1,2-bonded butadiene-derived unit out of a total of 100 mol % of decomposed components containing styrene-derived units and/or 1,2-bonded butadiene-derived units is less than 4 mol %; and (4) a vinyl content of a butadiene moiety is not less than 20% and less than 50%.
 2. The rubber composition according to claim 1, wherein the diene rubber further includes another diene rubber other than the styrene-butadiene copolymer.
 3. The rubber composition according to claim 1, wherein the reinforcing filler is at least one type selected from silica and carbon black.
 4. A pneumatic tire using the rubber composition described in claim
 1. 5. The pneumatic tire according to claim 4, wherein the rubber composition is used in a cap tread.
 6. The rubber composition according to claim 2, wherein the reinforcing filler is at least one type selected from silica and carbon black.
 7. A pneumatic tire using the rubber composition described in claim
 6. 8. The pneumatic tire according to claim 7, wherein the rubber composition is used in a cap tread. 